Continuously forming and transporting consolidatable resin coated particulate materials in aqueous gels

ABSTRACT

Methods of continuously forming and suspending consolidatable resin composition coated particulate material in a gelled aqueous carrier liquid and transporting the coated particulate material by way of the gelled aqueous carrier liquid to a zone in which the sand is consolidated. In accordance with the methods, substantially continuous streams of a gelled aqueous carrier liquid, uncoated particulate material, a resin composition which will subsequently harden and a surface active agent are admixed whereby the particulate material is continuously coated with the resin composition and suspended in the gelled aqueous carrier liquid.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention provides a method of continuously coating a particulatematerial with a resin in the presence of an aqueous gel. The product ofthe method, a resin-coated particulate material, is especially useful inthe treatment of subterranean oil and gas producing formations for thepurpose of forming consolidations of the particulate material therein.The consolidations function to help control loose formation sand and tohelp retain loose proppants placed in fractures formed therein.

2. Description of the Prior Art

Processes and techniques have been developed for consolidatingparticulate material, e.g., sand, into a hard permeable mass in asubterranean zone.

These processes are useful in treating a subterranean formationcontaining loose or incompetent sands which migrate with hydrocarbonsproduced therefrom. The consolidated particulate material reduces orprevents such migration when it is placed between the producingformation and the well bore penetrating the formation. The formation ofthe consolidated, permeable, particulate mass has been accomplished bycoating formation sand adjacent the well bore with a hardenable resin,and then causing the resin to harden. An alternate technique has been tocoat sand with a resin on the surface, to suspend the coated sand in acarrier liquid and then to pump the suspension by way of the well boreinto the formation containing loose or incompetent sands to deposit thecoated sand therein. The resin on the deposited sand is then caused orpermitted to harden whereby a consolidated, hard permeable mass isformed between the well bore and the loose or incompetent sands in theformation.

The previously developed methods have been used successfully inapplications featuring resin coating of particulate material by batchmixing of component streams, but these methods have not been desirablein applications which require the rapid coating of particulate materialsuspended in continuous streams of a carrier liquid. For example, it isoften necessary that resin-coated particulate material be continuouslycarried into a subterranean formation by a gelled aqueous carrier liquidfor a relatively long period of time in order to deposit theresin-coated material and hold it in place against the face of theformation or to deposit the material in fractures formed in theformation. In such applications, if the flow rate of the carrier liquidis reduced or interrupted, the resin coated particulate material carriedin the liquid can be deposited in undesired locations such as in surfaceequipment or in the well bore instead of in formation fractures or otherspecific desired locations.

The batch mixing methods for producing continuous streams of gelledaqueous carrier liquids containing resin coated particulate materialsare time-consuming and expensive and are attended by risks of flow rateinterruption or reduction. For example, U.S. Pat. No. 4,074,760describes a method of forming a consolidated particulate mass in asubterranean formation wherein sand, coated with a resin, is suspendedin a gelled aqueous carrier liquid. The carrier liquid is introducedinto a subterranean zone whereby the resin coated sand is deposited andsubsequently consolidated therein. The preparation of the suspension ofcarrier liquid and coated sand involves the batch mixing of components,i.e., the gelled aqueous carrier liquid containing sand is preparedseparately from the resin followed by the batch mixing of the two forthe period of time required to coat the sand with the resin.

U.S. Pat. No. 4,199,484 discloses a method of preparing a suspension ofa particulate material coated with an epoxy resin in a gelled aqueouscarrier liquid wherein the coating of the sand is carried out in thegelled aqueous carrier liquid. According to this method, the gelledcarrier liquid, sand and other components are first combined followed bythe addition of the epoxy resin with mixing whereby the epoxy resincoats the sand. The batch mixing of the components requires a period oftime, e.g., at least about 15 minutes to several hours to obtainsatisfactory coating of the particulate material before the slurry maybe introduced into a placement zone. These prior art methods for formingsuspensions of gelled aqueous carrier liquid and resin coatedparticulate material are not carried out on a substantiallyinstantaneous and continuous basis.

SUMMARY OF THE INVENTION

By the present invention, a method of rapidly and continuously forming aconsolidatable, resin-coated, particulate material in the presence of anaqueous gelled carrier liquid is provided to produce a gelled carrierliquid containing the coated particulate material suspended therein; thesuspension can be continuously introduced into a subterranean zone overan extended period of time.

The method is comprised of substantially continuously admixing streamsof gelled aqueous carrier liquid, particulate material, a resincomposition and a surface active agent. The particulate material issubstantially continuously coated with the resin and suspended in thegelled aqueous carrier liquid.

A substantially continuous stream of the gelled aqueous carrier liquidhaving the coated particulate material suspended therein can beintroduced into a subterranean formation over the period of timenecessary to deposit therein the quantity of coated particulate materialrequired to form the desired hard permeable mass. The resin on thecoated particulate material is then allowed to harden whereby thedeposit is consolidated into a hard permeable mass in the formation.

The method of the present invention and the various chemical componentsuseful therein are described in detail in the Description of PreferredEmbodiments which follows.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic illustration of one system of apparatus forperforming the methods of the present invention.

FIG. 2 is a schematic illustration of laboratory apparatus used forsimulating the performance of the methods the invention in the field.

DESCRIPTION OF PREFERRED EMBODIMENTS

In accordance with the methods of the present invention, a substantiallycontinuous stream of particulate material, e.g., sand, is substantiallyinstantaneously coated with a continuous stream of resin which willsubsequently harden; the coated particulate material is simultaneouslysuspended in a gelled aqueous carrier liquid. The resin has asufficiently long curing or working time to enable continuous depositionof the suspension of gelled aqueous carrier liquid and coatedparticulate material in a desired location of a subterranean zone.Subsequent hardening of the resin in the zone produces the desired hardpermeable mass of consolidated particulate material.

The gelled aqueous carrier liquids utilized in this invention are formedby hydrating polysaccharide polymer gelling agents in fresh water, brineor seawater. The polysaccharide polymer gelling agents useful havemolecular weights in the range of from about 100,000 to 4,000,000,preferably from about 600,000 to about 2,400,000, and are preferablycellulose or guar derivatives. The polymers include substituents such ashydroxy ethyl to give the necessary water hydration and gelcharacteristics to produce a clear aqueous gel having a viscosity of atleast about 30 centipoises (reading on Fann V.G. meter at 300 rpm).Preferred polymers include substituted carboxy and hydroxy alkylcellulose, such as hydroxyethylcellulose andcarboxymethylhydroxyethylcellulose, and substituted hydroxy alkyl guar,such as hydroxypropylguar. Most preferably, the gelling agent ishydroxypropylguar or carboxymethylhydroxypropyl guar having a molecularweight in the range of from about 100,000 to about 4,000,000, and havinga propylene oxide substitution (M.S.) of about 0.1 to about 0.7 molespropylene oxide per mole of mannose and galactose in the guar.

The gelled aqueous carrier liquid is preferably prepared by combiningthe polysaccharide polymer utilized with the aqueous liquid used in anamount in the range of from about 20 to about 120 pounds of polymer per1,000 gallons of water, brine or seawater to form a gelled aqueousliquid having a viscosity in the range of from about 10 centipoisesaqueous carrier liquid includes from about 30 to about 80 pounds ofgelling agent per 1000 gallons of water, brine or seawater, and has aviscosity of from about 15 to about 100 centipoises.

The gelled aqueous carrier liquid preferably contains a gel breakerwhich serves to reduce the viscosity of the gel at a time substantiallycoincident with the completion of the placement of the coatedparticulate material at the desired location in a subterraneanformation. That is, the gel breaker causes the gelled carrier liquid torevert to a low viscosity liquid which readily separates from thedeposited particulate material and leaks-off into permeable stratasurrounding the deposit location.

As mentioned above, breaking the gelled carrier liquid allows it toseparate from the particulate material and enter or filter intopermeable strata adjacent the deposit location. While a variety of gelbreakers which are well known in the prior art can be utilized, anenzyme-type breaker such as cellulase for a substituted cellulosegelling agent and a hemi-cellulase for a substituted galactomannangelling agent are preferred.

As is well known in the art, relatively small quantities of the enzymebreaker used are generally required, but as is well known in the art,the particular quantity depends upon the pH, temperature, and specifictime period required between addition of the gel breaker and thebreaking of the gel. As will be understood, the greater the quantity ofgel breaker used, the shorter will be such time period.

The gelled aqueous carrier liquid containing the coated sand can becrosslinked to increase its viscosity if desired.

A variety of surface active agents can be utilized to promotesubstantially instantaneous coating of particulate material with theresin in the presence of a gelled aqueous carrier liquid, but thepreferred surface active agent is a mixture of one or more cationicsurface active agents and one or more non-cationic surface activeagents. As used herein, a non-cationic surface active agent includes ablend of anionic and non-ionic surface active agents.

A surface active agent is the ingredient necessary to produce thesubstantially instantaneous coating of the particulate material with theepoxy resin in the presence of the gelled aqueous carrier liquid. Anon-cationic surface active agent will achieve the desired coating whencertain galactomannan gelling agents are utilized, but the preferredsurface active agent is a blend of cationic and non-cationic surfaceactive agents.

The cationic surface active agents useful herein are preferably thereaction product of an alcohol, epichlorohydrin and triethylenediaminewherein monohydric aliphatic alcohols having in the range of from about12 to about 18 carbon atoms are reacted with from 2 to 3 moles ofepichlorohydrin per mole of alcohol followed by reaction with an excessof triethylenediamine. The alcohol epichlorohydrin reaction productcontains an ethoxylation chain having pendent chlorides. The subsequentreaction with triethylenediamine provides a cationic and a tertiaryamine functionality to the resulting surfactant product.

The non-cationic surfactants are preferably ethoxylated fatty acidsproduced by reacting fatty acids containing from about 12 to about 22carbon atoms with from about 5 to about 20 moles of ethylene oxide permole of acid, most preferably from about 12 to about 18 moles ofethylene oxide per mole of acid, to produce a mixture of variousquantities of ethoxylated acids and unreacted acids.

When the gelling agent used herein is a cellulose derivative, then onepreferred surface active agent is a blend comprised of isopropylalcohol, the cationic agent described above and the non-cationic agentdescribed above wherein the weight ratio of cationic agent tonon-cationic agent in the blend is in the range of about 0.4 to 1, andpreferably about 0.6, parts by weight cationic agent per 1 part byweight non-cationic agent and wherein the weight ratio of isopropylalcohol to non-cationic agent in the blend is about 1 part by weightalcohol per 1 part by weight non-cationic agent.

When the gelling agent used herein is a galactomannan gum, then onepreferred surface active agent is a blend comprised of amyl alcohol, thecationic agent described above and the non-cationic agent describedabove wherein the weight ratio of cationic agent to non-cationic agentin the blend is in the range of about 0 to 1, and preferably about 0.2,parts by weight cationic agent per 1 part by weight non-cationic agentand wherein the weight ratio of amyl alcohol to non-cationic agent inthe blend is about 1 part by weight alcohol per 1 part by weightnon-cationic agent.

The alcohol constituent of the above described blends functions as asolubilizer and diluent for the cationic and non-cationic surfactants.Appropriate substitutes for amyl alcohol include other similar alcohols,for example isopropyl alcohol, n-hexanol and fusel oil.

A substantially continuous stream of the surface active agent utilizedis mixed with the gelled aqueous carrier liquid, the resin compositionand the particulate material at a rate whereby the amount of activesurface active agent present in the mixture is in the range of fromabout 0.25 to about 10.0 gallons of surface active agent per 1000gallons of gelled aqueous carrier liquid. Most preferably, when agalactomannan gelling agent is used, the active surface active agent ispresent in the mixture in an amount of about 0.5 gallon per 1000 gallonsof gelled aqueous carrier liquid; when a cellulose derivative gellingagent is used, the active surface active agent is present in an amountof about 2 gallons per 1000 gallons of gelled aqueous carrier liquid.

Various types of particulate material can be used in accordance with thepresent invention, e.g., sand, sintered bauxite, etc. The preferredparticulate material is sand, the particle size of which being in therange of from about 10 to about 70 mesh U.S. Sieve Series, with thepreferred sizes being 10-20 mesh, 20-40 mesh or 40-60 mesh, or 50-70mesh depending upon the particle size and distribution of formation sandadjacent to which the resin coated sand is to be deposited.

A substantially continuous stream of sand is combined with the gelledaqueous carrier liquid-surface active agent-resin composition mixture ata rate whereby the amount of sand present in the mixture is in the rangeof from about 2 to about 20 pounds of sand per gallon of gelled aqueouscarrier liquid. Most preferably, the sand is present in the mixture inan amount in the range of from about 3 to about 15 pounds per gallon ofcarrier liquid.

The resin composition utilized in accordance with this invention forsubstantially instantaneously coating particulate material in thepresence of the above-described surface active agent and gelled aqueouscarrier liquid is comprised of a hardenable polyepoxide resin (epoxyresin), a solvent system, a hardener, a coupling agent, and a hardeningrate controller. The polyepoxide resin, the hardener and the couplingcomponents of the resin agent composition substantially instantaneouslycoat the particulate material in the presence of the gelled aqueouscarrier liquid and the surface active agent.

The resin composition, above defined, is present in the mixture ofingredients in the range of from about 1.00 to about 20 pounds of resincomposition per each 100 pounds of particulate material. It is believedthat the density of the resin composition will vary in the range fromabout 1.05 to about 1.16 grams per milliliter depending upon thespecific content of the composition.

While various polyepoxide resins can be utilized, preferred resins arethe condensation products of epichlorohydrin and bisphenol A. Acommercially available such product is marketed by the Shell ChemicalCompany of Houston, Tex., under the trade name EPON 828. EPON 828 resinexhibits good temperature stability and chemical resistance and has aviscosity of about 15,000 centipoises.

In one preferred embodiment, the solvent system is comprised of a first,polar, organic diluent which, in all cases, is miscible with thepolyepoxide resin and substantially immiscible with water, and a secondpolar, organic, diluent which, in all cases, is miscible with butsubstantially non-reactive with the polyepoxide resin. The first andsecond diluents are present in the resin composition in amountssufficient to adjust the viscosity of the resin composition to a levelin the range of from about 100 centipoises to about 800 centipoises.

The first polar organic diluent is present in the resin composition inthe range of from about 2 to about 35, preferably from about 15 to about30, and most preferably about 28 parts by weight per 100 parts by weightof the epoxy resin component. The second polar organic diluent ispresent in the resin composition in the range of from about 4 to 20,preferably from about 8 to 15 and most preferably about 10 parts byweight per 100 parts by weight of the epoxy resin component.

In a more preferred system, the second polar organic diluent is alsosubstantially immiscible with water.

In the most preferred system, the first polar organic diluent is alsosubstantially reactive with the epoxy resin component.

The preferred first polar organic diluent which is reactive with theepoxy resin component is selected from the group consisting of butylglycidyl ether, cresol glycidyl ether, allyl glycidyl ether, phenylglycidyl ether or any other glycidyl ether which is miscible with theepoxy resin. Of these, butyl glycidyl ether and ortho-cresol glycidylether are the most preferred. The reactive diluent reacts with thehardening agent and also functions to reduce the viscosity of the epoxyresin.

The second polar organic diluent which is not reactive with the epoxyresin component is essential because it contributes to the lowering ofthe viscosity of the resin, and, in combination with the surface activeagent, brings about the substantially instantaneous coating of theparticulate material with the resin in the presence of the gelledaqueous carrier liquid.

The preferred non-reactive diluent is of low molecular weight, ismiscible with the epoxy resin, is substantially immiscible with waterand is selected from the group consisting of compounds having thestructural formula: ##STR1## wherein: R is (C_(n) H_(2n+1)) and n is aninteger in the range of from about 1 to about 5;

R₁ is (C_(m) H_(2m+1)) and m is 0 or an integer in the range of from 1to about 4, or ##STR2## and y is an integer in the range of from 1 toabout 4, and X is independently H or OH; and

R₂ is C_(a) H_(2a) and a is an integer in the range of from 2 to about5.

Of the various compounds falling within the group described above, ethylacetate, butyl lactate, ethyl lactate, amyl acetate, ethylene glycoldiacetate and propylene glycol diacetate are preferred. Of these, butyllactate is the most preferred. Butyl lactate has a molecular weight of130 and a water solubility of 1 gram per 1,000 grams of water.

Methyl alcohol, which is partially soluble in the polyepoxide resin, andother low molecular weight alkanols also are useful second diluents.

Other chemicals such as tetrahydrofurfuryl methacrylate and ethylacetate can be either the first or the second polar organic diluent aseach of these do satisfy the definitions of both types of diluents asset out above.

A variety of hardening agents can be used in this invention to cause thehardening of the resin. Examples of such hardening agents includeamines, polyamines, amides and polyamides known to those skilled in theart. A preferred hardening agent is methylene dianiline, eitherdissolved in a suitable solvent such as ethyl acetate or in a liquideutectic mixture of amines diluted with methyl alcohol. A particularlypreferred hardening agent is a liquid eutectic mixture of amines dilutedwith about 22% by weight methyl alcohol, the eutectic mixture containingabout 79% by weight methylene dianiline with the remaining amines beingcomprised of primary aromatic amines and meta-phenylene diamine. Such aliquid eutectic mixture is commercially available under the trade nameTONOX 22 from the Uniroyal Chemical Co. of Naugatuck, Conn.

The quantity of hardening agent useful herein is dependent to a greatextent upon the chemical nature of the hardener itself. It is,accordingly, difficult to specify in detail the amount of hardener to beused. However, in a broad sense, it is believed that the hardener ispresent in the range of from about 2 to about 150 parts by weight per100 parts by weight of epoxy resin. When the hardener is an aromaticamine, the weight range is from about 8 to about 50. One aromatic amine,methylene dianiline, is useful when present in the range of from about25 to about 38 parts by weight per 100 parts by weight of epoxy resin.When the hardener is an aliphatic amine, for example adimethylaminomethyl substituted phenol, the hardener weight range isfrom about 2 to about 15 parts by weight per 100 parts by weight ofepoxy resin.

The mixture of ingredients also preferably includes aresin-to-particulate material coupling agent to promote bonding of theresin to the particulate material such as a functional silane.Preferably, a N-beta-(aminoethyl)-gamma -aminopropyltrimethoxysilaneresin-to-sand coupling agent is included in an amount in the range offrom about 0.1 to about 2 parts by weight per 100 parts by weight ofepoxy resin. A commercially available product is Union Carbide SilaneA-1120 (Danbury, Conn.).

The mixture can also include retarders or accelerators as hardening ratecontrollers to lengthen or shorten the working and cure times of theresin. When retarders are used, low molecular weight organic acid esterretarders are preferred. Examples of such retarders are alkyl esters oflow molecular weight alkyl acids containing about 2 to 3 carbon atoms.Suitable accelerators include 2,4,6-tris dimethyl amino methyl phenol,the ethyl hexonate salt thereof, and weak organic acids such as fumaric,erythorbic, ascorbic, salicylic and maleic acids. If a retarder oraccelerator is utilized, it is combined therewith in an amount up toabout 0 to 10 parts by weight per 100 parts by weight of epoxy resin.

As mentioned above, if it is desired to increase the viscosity of thegelled aqueous carrier liquid-resin composition coated particulatematerial slurry, a continuous stream of liquid crosslinker can becombined with the slurry depending upon the type of gelling agentutilized. Examples of crosslinkers which can be utilized are thoseselected from the group consisting of titanium, aluminum, zirconium andborate salts. Preferred crosslinkers are titanium lactate, titaniumtriethanolamine, aluminum acetate and zirconium salts. Generally, thecrosslinker used is in the form of a solvent containing solution whichis combined with the slurry at a rate which results in the crosslinkerbeing present in an amount equivalent to the range of from about 0.05 toabout 5.0 gallons of an approximately 30% by weight solution of thecrosslinker per 1000 gallons of gelled aqueous carrier liquid. Also,depending upon the particular crosslinker used, a pH buffering agent maybe combined with the gelled aqueous carrier liquid-coated particulatematerial slurry.

Based upon 100 parts by weight of epoxy resin, the resin composition ispreferably comprised of the above-described epichlorohydrin-bisphenol Aepoxy resin (100 parts by weight), a water immiscible reactive diluentcomprised of ortho-cresol glycidyl ether present in an amount in therange of from about 20 parts by weight to about 35 parts by weight, anonreactive diluent comprised of butyl lactate present in an amount inthe range of from about 4 parts by weight to about 12 parts by weightand a hardening agent comprised of a water miscible solvent dilutedliquid eutectic mixture of primary aromatic amines, methylene dianilineand metaphenylene diamine present in an amount in the range of fromabout 25 parts by weight to about 45 parts by weight. When the waterimmiscible reactive diluent used in the resin composition is butylglycidyl ether instead of ortho-cresol glycidyl ether, it is present inan amount in the range of from about 2 parts by weight to about 20 partsby weight.

The above-described resin composition has a viscosity in the range offrom about 400 centipoises to about 150 centipoises, and has anapproximate working time without retarders or accelerators present,i.e., a time period between mixing and when the viscosity of thecomposition exceeds about 1500 centipoises, of about 2 hrs. at normalambient conditions (about 72° F.). The cure time for the resincomposition, i.e., the time from when the viscosity reaches about 1500centipoises to when the resin composition has fully hardened is about 80hrs. at 72° F.

A specific preferred resin composition for use in accordance with thepresent invention is comprised of 100 parts by weight of anepichlorohydrin and bisphenol A epoxy resin, butyl glycidyl etherpresent in an amount of about 11 parts by weight, butyl lactate presentin an amount of about 8 parts by weight, a liquid eutectic mixture ofprimary aromatic amines, methylene dianiline and metaphenylene diaminediluted with about 22% by weight methyl alcohol present in an amount ofabout 36 parts by weight, N-beta(aminoethyl)-gamma-aminopropyltrimethoxysilane present in an amount ofabout 0.8. parts by weight, and the ethyl hexonate salt of dimethylamino methyl phenol present in an amount of about 7 parts by weight.This resin composition has a viscosity of about 200 centipoises, aworking time of about 0.5 hours and a cure time of about 8 hrs. at 80°F. When the accelerator (ethyl hexonate salt of dimethyl amino methylphenol) is not present in the composition, it has a working time ofabout 2.0 hrs. and a cure time of about 84 hrs.

In carrying out the method of the present invention, and referring toFIG. 1, an aqueous gelled carrier liquid is first prepared in acontainer 10 by combining a polysaccharide polymer of the type describedabove with fresh water, brine or seawater. The water and polymer arecarefully mixed with slow agitation whereby the polymer is hydrated.Alternatively, the gel may be made from a concentrated solution ofgelling agent as is known to those skilled in the art.

A substantially continuous stream of the aqueous gelled carrier liquidfrom the container 10 is conducted by way of a conduit 12 to a mixingtub 14. Simultaneously, a continuous stream of liquid surface activeagent of the type described above is preferably conducted from acontainer 16 to the conduit 12 by way of a conduit 18 connectedtherebetween.

A substantially continuous stream of particulate material, e.g., sand,is conducted to the mixing tub 14 from a container 20 by a conveyor 22connected therebetween.

The liquid epoxy resin composition described above may be premixed in acontainer 24, and a substantially continuous stream thereof iscontinuously conducted therefrom to the mixing tub 14 by way of aconduit 26 connected therebetween.

Simultaneously with all of the above-described streams of components, asubstantially continuous stream of liquid gel breaker is preferablyconducted from a container 28 to the conduit 12 by a conduit 30. Theliquid gel breaker combines with the gelled aqueous carrier liquid andthe surface active agent flowing through the conduit 12 and is conductedtherewith to the mixing tub 14.

As indicated in the drawing, the liquid gel breaker or a powdered solidgel breaker can optionally be introduced directly into the mixing tub14. Occasionally the gel breaker is handled in a solid form, either as apowder or as an adsorbate on inert particles, such as sand, salt orsugar. These can be directly introduced into the mixing tub. If desiredto provide this flexibility, the conduit 30 can contain a shut-off valve32, and a conduit 34 having a shut-off valve 36 disposed therein canconnect the conduit 30 upstream of the shut-off valve 32 to the mixingtub 14 whereby the liquid gel breaker can be introduced directly intothe mixing tub. However, as will be understood by those skilled in theart, any container-conduit arrangement can be utilized which brings thecomponent streams described into the mixing tub 14 or equivalent mixingapparatus simultaneously.

The component streams are intimately mixed in the mixing tub 14 andremain therein for a residence time of approximately 10 seconds. Duringsuch time, the particulate material is coated with the resin compositionand suspended in the gelled aqueous carrier liquid.

The gelled aqueous carrier liquid-resin coated particulate materialslurry formed in the mixing tub 14 is withdrawn therefrom by way of aconduit 38 which conducts a continuous stream of the slurry to one ormore pumps 40. A conduit 42, connected to the discharge of the pumps 40,conducts the slurry to a conduit system disposed in a well bore and to asubterranean zone wherein the resin coated particulate material is to bedeposited and consolidated into a hard permeable mass. If a crosslinkeris utilized, it is added to the slurry downstream of the mixing tub 14,i.e., the crosslinker is conducted from a container 44 to the conduit 38by a conduit 46 connected therebetween.

The resin coated particulate material can be utilized in the performanceof gravel packing procedures or as a proppant material in fracturingtreatments performed upon a subterranean formation. The resin coatedparticulate also can be utilized in the formation of controlledpermeability synthetic formations within a zone of a subterraneanformation.

A significant aspect of the methods of this invention is the ability tosubstantially instantaneously coat the particulate material with theresin composition and continuously suspend the coated particulatematerial in a continuous stream of gelled aqueous carrier liquid. Thisis accomplished by the particular resin composition and combination ofcomponent streams which promote the coating of the resin composition onthe particulate material. The continuous stream of gelled aqueouscarrier liquid-resin coated particulate material slurry formed isgenerally insensitive to variations in pH within the range of from about5 to about 8.5 and variations in temperature within the range of fromabout 45° F. to about 100° F. The cure time of the resin composition canbe short, i.e., less than about 6 hrs., and the resin composition canaquire substantial strength rapidly, i.e., within a time period of about12 hours or less.

As is well understood by those skilled in the art, it may be desirableto condition the formation adjacent the consolidation placement locationby preflushing the formation. Also, after-flushes may be used to insureuniform placement, consolidation and maximum permeability of thedeposited particulate material as well as of particulate materialexisting in the formation.

In order to further illustrate the methods of the present invention andfacilitate a clear understanding thereof, the following examples aregiven.

Tests are performed to determine the effectiveness of various resincompositions containing various reactive and non-reactive diluents tocoat sand and to produce highstrength consolidations therefrom in thepresence of water gelled with various gelling agents.

EXAMPLE 1

    ______________________________________                                        Formulation:                                                                  ______________________________________                                        Tap water               1     liter                                           Potassium chloride      20    grams                                           Sodium diacetate        1.2   grams                                           Hydroxypropyl guar.sup.1 (HPG)                                                                        4.8   grams                                           Fumaric acid            0.5   grams                                           ______________________________________                                         .sup.1 Contains 0.39 moles propylene oxide substituents per pyranose unit                                                                              

Procedure

The tap water, potassium chloride and sodium diacetate are mixed toproduce a solution. The hydroxypropyl guar (HPG) is then added to thesolution and stirred. Thereafter, the fumaric acid is added. Theresulting mixture is then permitted to stand overnight in a coveredcontainer. The pH of the formed gel is in the range of about 6.8 toabout 7.5.

Tests are conducted using samples of the HPG gel formed above, togetherwith other ingredients.

    ______________________________________                                        Formulation:                                                                  HPG gel             250.00  ml                                                Surfactant mixture.sup.1                                                                          0.25    ml                                                Resin composition.sup.2                                                                           21.00   ml (1.148 gm/ml)                                  Ottawa Sand 40/60 mesh (USS)                                                                      450.00  grams                                             1 Surfactant Mixture:                                                         Amyl alcohol        45      parts by weight                                                               of mixture                                        Cationic surface active agent                                                                     10      parts by weight                                   (previously described)      of mixture                                        Non cationic surface active agent                                                                 45      parts by weight                                   (previously described)      of mixture                                        2 Resin Composition:                                                          EPON 828 (Shell Chemical Com-                                                                     100     parts by weight                                   pany) reaction product of                                                     epichlorohydrin and                                                           Bisphenol A                                                                   Hardener Blend      42      parts by weight                                   eutectic mixture of primary                                                   aromatic amines, meta-                                                        phenylene diamine, methylene                                                  dianiline (about 78% by weight                                                of hardener blend)                                                            methyl alcohol (about 22% by                                                  weight of hardener blend)                                                     Silane Coupling Agent                                                                             0.66    parts by weight                                   N--beta-(aminoethyl)-gamma-                                                   aminopropyltrimethoxysilane                                                   Diluent 1                   Variable parts                                                                by weight                                         Diluent 2                   Variable parts                                    non-reactive diluent (varies)                                                                             by weight                                         ______________________________________                                    

Procedure

The ingredients are mixed together to form slurries each of which isstirred for two minutes in a beaker and then transferred to a laboratoryconsistometer cup and stirred for an additional 60 minutes. Each slurryis examined visually and poured into one or more tubes to permitconsolidation of the sand. The consolidation tubes are glass tubescoated with mold release agent and stoppered at one end. The sand ineach slurry within each tube is tamped down and allowed to cure for 20hours at the temperature indicated in Table I. After curing, the glasstubes are broken and the consolidated sand samples are tested forcompressive strength. The results of these tests are given in Table Ibelow.

                                      TABLE I                                     __________________________________________________________________________    COMPRESSIVE STRENGTH OF SAND CONSOLIDATIONS                                                                    Cure                                         Diluent 1          Diluent 2     Tempera-                                                                            Compressive                            Run          Parts         Parts ture, Strength,                              No.                                                                              Chemical  By Weight.sup.1                                                                     Chemical                                                                              By Weight.sup.1                                                                     °F.                                                                          psi                                    __________________________________________________________________________    1  butyl glycidyl ether                                                                    27    butyl lactate                                                                         7     170   5500                                   2  butyl glycidyl ether                                                                    14    methyl alcohol                                                                        7     170   5340                                   3  butyl glycidyl ether                                                                    13    methyl alcohol                                                                        7     120   3600                                   4  butyl glycidyl ether                                                                    14    ethyl acetate                                                                         14    170   3560                                   5  butyl glycidyl ether                                                                    30    THFMA.sup.2                                                                           7     170   2100                                   6  THFMA.sup.2                                                                             11    methyl alcohol                                                                        6     170   2000                                   7  ethyl acetate                                                                           14.5  methyl alcohol                                                                        5     120   1600                                   8  ethyl acetate                                                                           10    methyl alcohol                                                                        5     120   1560                                   9  ethyl acetate                                                                           25    methyl alcohol                                                                        6     170   1470                                   10 --              ethyl acetate                                                                         28    120    400                                   __________________________________________________________________________     .sup.1 Based on 100 parts by weight of epoxy resin                            .sup.2 tetrahydrofurfuryl methacrylate                                   

From Table I it can be seen that the consolidations having the highestcompressive strength contain both a reactive and a non-reactive diluentin the resin composition and that when the resin composition contains abutyl glycidyl ether reactive diluent and butyl lactate non-reactivediluent, an excellent consolidation is achieved.

EXAMPLE 2

Tests are conducted to determine the sand coating times of various resincompositions in the presence of water gelled with hydroxypropylguar anda surfactant.

250 cc samples of aqueous gel containing surfactant and 40-60 meshOttawa sand are prepared in accordance with the procedure and in thequantities described in Example 1. The resin compositions described inTable II below are prepared and added to the gel surfactant sand samplesin amounts of 28 ml of resin composition per sample. After adding theresin composition, each mixture is stirred in a beaker and the time forcoating to take place determined by visual observation. That is, theresin composition is deemed to coat when resin does not remain in thegel when stirring is stopped. Excess resin is easily visible if coatinghas not occurred as it settles in a layer on top of the sand with thegelled water above the resin.

In tests 3, 4 and 5, using the same resin composition, the stirring isstopped after 5, 10 and 60 second intervals and the samples immediatelytransferred to consolidation tubes, cured at 170° F. and tested forcompressive strength. The results of these tests are given in Table IIbelow.

                  TABLE II                                                        ______________________________________                                        COATING TIMES OF VARIOUS RESIN COMPOSITIONS                                                    Amount                                                                        in Resin                                                          Resin       Composition,                                                 Test Formulation Parts by   Mixing  Compressive                               No.  Components  Weight     Time    Strength                                  ______________________________________                                        1    epoxy.sup.1,3                                                                             55         about 5 sec.                                                                          Not run -                                      butyl lactate                                                                             4                  sample                                         cresyl glycidyl                                                                           15                 coated                                         ether                                                                         methyl alcohol                                                                            6                                                                 hardener.sup.2                                                                            20                                                           2    epoxy.sup.1,3                                                                             55         1 to 5 sec.                                                                           Not run -                                      butyl lactate                                                                             4                  sample                                         cresyl glycidyl                                                                           15                 coated                                         ether                                                                         methyl alcohol                                                                            6                                                                 hardener.sup.2                                                                            20                                                           3    epoxy resin.sup.1,3                                                                       55         5 sec   2206 psi                                       butyl lactate                                                                             4                                                                 cresyl glycidyl                                                                           15                                                                ether                                                                         methyl alcohol                                                                            6                                                                 hardener.sup.2                                                                            20                                                           4    epoxy resin.sup.1,3                                                                       55         10 sec  2950 psi                                       butyl lactate                                                                             4                                                                 cresyl glycidyl                                                                           15                                                                ether                                                                         methyl alcohol                                                                            6                                                                 hardener.sup.2                                                                            20                                                           5    epoxy resin.sup.1,3                                                                       55         60 sec  3100 psi                                       butyl lactate                                                                             4                                                                 cresyl glycidyl                                                                           15                                                                ether                                                                         methyl alcohol                                                                            6                                                                 hardener.sup.2                                                                            20                                                           ______________________________________                                         .sup.1 Shell Chemical Co., EPON 828                                           .sup.2 Liquid eutectic mixture of primary aromatic amines, methylene          dianiline (79% by weight) and metaphenylene diamine.                          .sup.3 All tests had 0.5 parts by weight                                      N--beta(aminoethyl)-gamma-aminopropyltrimethoxysilane                    

EXAMPLE 3

A test is run to determine the compressive strength of a sandconsolidation formed in accordance with the present invention at atemperature of 250° F. A gelled aqueous carrier liquid is prepared byadding 9.6 grams of hydroxyethylcellulose (D.S. of 2.5) to one liter offresh water having 30 grams of potassium chloride dissolved therein.After hydration of the hydroxyethylcellulose, 4 ml of a surfactant blendcomprised of 50 parts by weight amyl alcohol, 37 parts by weight noncationic surfactants and 13 parts by weight cationic surfactants iscombined with the aqueous gel followed by 1800 grams of 40-60 mesh (U.S.Sieve Series) Ottawa sand and 84 ml of the resin composition describedin Table III below.

The resulting slurry is stirred in a beaker for 2 minutes and thentransferred to a laboratory consistometer cup and stirred for anadditional 60 minutes. After stirring, the slurry is poured into aconsolidation tube and allowed to cure in the same manner as describedin Example 1 for 48 hours at 170° F. The temperature is then graduallyraised to 250° F. and the sample is allowed to cure for an additional 48hours. After curing, the consolidation is cooled over a 4-hour period toroom temperature, trimmed, and prepared for compressive strengthtesting. The sample is then gradually reheated to 250° F., at whichtemperature compression strength testing is carried out. The results ofthis test are given in Table III below.

                  TABLE III                                                       ______________________________________                                        COMPRESSIVE STRENGTH OF SAND CONSOLIDATION                                    Resin Composition                                                                          Amount, Parts                                                                             Compressive Strength                                 Components   by Weight   at 250° F.                                    ______________________________________                                        epoxy.sup.1  60.0        2510 psi                                             butyl lactate                                                                              5.0                                                              butyl glycidyl ether                                                                       6.0                                                              Hardener.sup.2                                                                             21.0                                                             coupling agent.sup.3                                                                       0.5                                                              methyl alcohol                                                                             7.0                                                              ______________________________________                                         .sup.1 Shell Chemical Co. EPON 828                                            .sup.2 Liquid eutectic mixture of primary aromatic amines, methylene          dianiline (about 79% by weight) and metaphenylene diamine                     .sup.3 N--beta(aminoethyl)-gamma-aminopropyltrimethoxysilane             

EXAMPLE 4

Tests are conducted to determine the effect of order of addition ofcomponents on the compressive strengths of the consolidations formed.

A gelled aqueous liquid is formed utilizing hydroxy-ethylcellulose inaccordance with the procedure set forth in Example 1. To 250-millilitersamples of the aqueous gel, surfactant described in Example 1, sanddescribed in Example 1, the resin composition of Table III and anaccelerator comprised of 2,4,6-tris dimethyl amino methyl phenol areadded to the aqueous gel in various orders of introduction. Theresulting slurries are each stirred for one minute in a beaker and thentransferred to a laboratory consistometer cup and stirred for anadditional 60 minutes. Each slurry is then poured into a consolidationtube and allowed to cure for the time and at the temperature indicatedin Table IV below. The compressive strength of the resultingconsolidations are determined.

The results of these tests are given in Table IV below.

                  TABLE IV                                                        ______________________________________                                        EFFECT OF ORDER OF ADDITION ON COMPRESSIVE                                    STRENGTH OF CONSOLIDATIONS                                                                                Com-                                                               Cure       pressive                                          Order of Addition to Gel                                                                         Time,   Tempera- Strength,                                 1       2        3         hr    ture, °F.                                                                     psi                                   ______________________________________                                        Surfactant                                                                            Sand     Resin     20     80    2840                                                   (including                                                                    DMP-30.sup.1)                                                Surfactant                                                                            Sand     Resin     20    100    3160                                                   (including                                                                    DMP-30)                                                      Surfactant                                                                            Sand     Resin     20    140    3940                                                   (including                                                                    DMP-30)                                                      Surfactant                                                                            Sand     Resin     48    140    5660                                                   (including                                                                    DMP-30)                                                      Surfactant                                                                            Sand     Resin     20     80    1220                                  and                                                                           DMP-30                                                                        Surfactant                                                                            Resin (in-                                                                             Sand      24    120    5360                                          cluding                                                                       DMP-30)                                                               ______________________________________                                         .sup.1 DMP30 is 2,4,6tris dimethylamino methyl phenol, an accelerator.   

EXAMPLE 5

The laboratory system illustrated schematically in FIG. 2 is used tosimulate the equipment used in acutal field operations and for carryingout the methods of this invention. The system is comprised of a gelledaqueous carrier liquid container 50 connected by tubing 52 to thesuction connection of a 1/3 horsepower, 3,425 rpm centrifugal feed pump54. A shut-off valve 56 is disposed in the tubing 52.

A liquid surfactant blend container 58 is connected to the suctionconnection of a concentric cam fluid metering pump 60 by tubing 62having a shut-off valve 64 therein. The discharge connection of the pump60 is connected to the tubing 52 by tubing 66. The discharge connectionof a 50 cc syringe pump 68 for injecting liquid gel breaker is connectedby tubing 70 to the tubing 52.

The discharge connection of the feed pump 54 is connected by tubing 72to a 450 cc over-flow mixing tub 74 equipped with an electric stirrer76.

A liquid resin composition container 78 is connected to the inletconnection of a concentric cam fluid metering pump 80 by tubing 82having a shut-off valve 84 disposed therein. The discharge of the pump80 is connected by tubing 86 to the tubing 72.

A sand container 88 is positioned above the mixing tub 74 having a sandoutlet 90. A shut-off valve 92 is disposed in the outlet 90 which ispositioned to introduce sand into the mixing tub 74.

When a test run is made, the valves 56, 64, and 84 are opened and thepumps 54, 60, 68 and 80 are started whereby continuous streams of gelledaqueous carrier liquid, resin composition, surfactant blend and gelbreaker, at desired flow rates, are pumped into the mixing tub 74.Simultaneously, a continuous stream of sand is introduced into themixing tub 74 by way of valve 92 and outlet 90 at a desired flow rate.The stirrer 76 is activated whereby a gelled aqueous carrierliquid-resin coated sand slurry is formed in the mixing tub 74.

The slurry produced in the mixing tub 74 overflows the tub conducted byway of tubing 94 connected thereto and to an air-powered opposed pistondischarge pump 96. The discharge connection of the pump 96 is connectedby tubing 98 to a container 100 for receiving the slurry.

A liquid crosslinker container 102 is connected by tubing 104 to theinlet connection of a high pressure pump 108. A shut-off valve 106 isdisposed in the tubing 104 and a tubing 110 connects the dischargeconneciton of the pump 108 to the tubing 94. When a crosslinker iscombined with the slurry flowing through the pump 96 into the receiver100, it is injected into the slurry by way of the pump 108, tubing 110and tubing 94 at a controlled continuous flow rate.

The various component streams and flow rates thereof utilized incarrying out the tests using the laboratory apparatus described aboveare as follows:

Gelled aqueous carrier liquid is introduced into the container 50. Thegelled aqueous carrier liquid is comprised of a 2% KCl brine gelled withhydroxypropylguar in an amount of 40 pounds per 1,000 gallons of brine.The gelled aqueous carrier liquid is conducted from the container 50 tothe feed pump 54 at a flow rate of 1/2 gallon per minute to 1 gallon perminute whereby continuous flow can be sustained for about 20 minutesbefore refilling of the container 50 is necessary.

The liquid resin composition used is described in Example 3. The resincomposition is introduced into the container 78, and the flow rate ofresin composition pumped the pump 80 is varied up to 56 cc per minute.Sand from the container 88 is introduced into the mixing tub 74 at avaried rate of 1 pound to 4 pounds per minute whereby a resin-to-sandratio of about 0 to 0.6 gallons of resin composition per 100 pounds ofsand results in the mixing tub 74.

The liquid surfactant blend described in Example 1 is introduced intothe container 58 and pumped to the feed pump 54 at a rate in the rangeof from 0.0 cc per minute to 8.4 cc per minute.

The liquid gel breaker utilized is an enzyme breaker of a typepreviously described herein and is used as a 1 gram per 100 cc aqueoussolution. The solution is introduced to the feed pump 54 at the rate of10 cc per minute.

The crosslinker utilized is prepared by diluting a solution of titaniumtriethanolamine with 50% by volume tap water at least 30 minutes and notmore than 2 hours before use. When used, the crosslinker is pumped intothe slurry flowing through the tubing 94 at a rate equivalent to about 0to about 0.8 cc of crosslinker per liter of slurry.

Gelled aqueous carrier liquid-resin coated particulate slurries areformed in the mixing tub 54 and colmaterial lected in the slurryreceiver 100. Portions of the slurries are poured into consolidationtubes and compressive strength tests are conducted as described inExample 1. The results of these tests with and without cross-linker aregiven in Table V below.

                                      TABLE V                                     __________________________________________________________________________    Amount of Amount of                                                                              Amount of Gel                                                                          Amount of Cross-                                                                       Amount                                   Resin Composition                                                                       Surfactant Used,                                                                       Breaker Used,.sup.1                                                                    linker Used,                                                                           of Sand Used, lb.                                                                      Cure Compres-                   Used, cc per Liter                                                                      cc per Liter of                                                                        cc per Liter of                                                                        cc per Liter of                                                                        per Gallon of                                                                          Temper-                                                                            sive                       of Gelled Aqueous                                                                       Gelled Aqueous                                                                         Gelled Aqueous                                                                         Gelled Aqueous                                                                         Gelled Aqueous                                                                         ature,                                                                             Strength                   Carrier Liquid                                                                          Carrier Liquid                                                                         Carrier Liquid                                                                         Carrier Liquid                                                                         Carrier Liquid                                                                         °F.                                                                         psi                        __________________________________________________________________________    10        1        1        .4       4        170   50                        10        4        1        0        4        170  150                        11        4        1        .4       2        170  158                        __________________________________________________________________________     .sup.1 Gel breaker diluted 1 g/100 cc tap water.                         

EXAMPLE 6

The procedure of Example 5 is repeated except that the amount ofsurfactant used, the amount of crosslinker used and the cure temperatureare varied. The results of these tests are given in Table VI below.

                                      TABLE VI                                    __________________________________________________________________________    COMPRESSIVE STRENGTHS USING VARYING AMOUNTS                                   OF SURFACTANT AND CROSSLINKER                                                 Amount of Amount of                                                                              Amount of Gel                                                                          Amount of Cross-                                                                       Amount                                   Resin Composition                                                                       Surfactant Used,                                                                       Breaker Used,.sup.1                                                                    linker Used,                                                                           of Sand Used, lb.                                                                      Cure Compres-                   Used, cc per Liter                                                                      cc per Liter of                                                                        cc per Liter of                                                                        cc per Liter of                                                                        per Gallon of                                                                          Temper-                                                                            sive                       of Gelled Aqueous                                                                       Gelled Aqueous                                                                         Gelled Aqueous                                                                         Gelled Aqueous                                                                         Gelled Aqueous                                                                         ature,                                                                             Strength                   Carrier Liquid                                                                          Carrier Liquid                                                                         Carrier Liquid                                                                         Carrier Liquid                                                                         Carrier Liquid                                                                         °F.                                                                         psi                        __________________________________________________________________________    15        2.7      1        0        4         72  150                        15        4.5      1        0        4         72  500                        15        4.5      1        0.8      4        170  670                        15        2.5      1        0.8      4        170  785                         0        1.5      1        0.8      4        170   0                         __________________________________________________________________________     .sup.1 Gel breaker diluted, 1 g/100 cc tap water                         

EXAMPLE 7

The procedure of Example 6 is repeated except that the surfactantutilized is comprised of an aqueous 50 parts by weight amyl alcoholsolution having the cationic surface active agents described previouslyherein dissolved therein in an amount of abaout 7 parts by weight, andthe non-cationic surface active agents described previously dissovledtherein in an amount of about 43 parts by weight; the crosslinker istitanium triethanolamine; and the sand concentration is varied. Theresults of these tests are given in Table VII below.

                                      TABLE VII                                   __________________________________________________________________________    COMPRESSIVE STRENGTHS USING VARYING AMOUNTS                                   OF SURFACTANT AND CROSSLINKER                                                 Amount of Amount of                                                                              Amount of Gel                                                                          Amount of Cross-                                                                       Amount                                   Resin Composition                                                                       Surfactant Used,                                                                       Breaker Used,.sup.1                                                                    linker Used,                                                                           of Sand Used, lb.                                                                      Cure Compres-                   Used, cc per Liter                                                                      cc per Liter of                                                                        cc per Liter of                                                                        cc per Liter of                                                                        per Gallon of                                                                          Temper-                                                                            sive                       of Gelled Aqueous                                                                       Gelled Aqueous                                                                         Gelled Aqueous                                                                         Gelled Aqueous                                                                         Gelled Aqueous                                                                         ature,                                                                             Strength                   Carrier Liquid                                                                          Carrier Liquid                                                                         Carrier Liquid                                                                         Carrier Liquid                                                                         Carrier Liquid                                                                         °F.                                                                         psi                        __________________________________________________________________________    28        2        1        0        4        170  3910                       15        2        1        0.8      4        170   934                       15        3        1        0.8      2        170   550                       15        3        1        0        4        170  1070                       __________________________________________________________________________     .sup.1 Gel breaker diluted, 1 g/100 cc tap water.                        

EXAMPLE 8

The procedure of Example 6 is repeated except that the gelled aqueouscarrier liquid is formed using 50 pounds of hydroxyethylcellulose per1,000 gallons of brine, the gel breaker is an aqueous enzyme breakersolution (1 gram cellulase per 100 cc) and the surfactant is an aqueous50 parts by weight isopropyl alcohol solution having the cationicsurface active agents described previously herein dissolved therein inan amount of about 20 parts by weight, and the non-cationic surfaceactive agents described previously dissolved therein in an amount ofabout 30 parts by weight. The results of these tests are given in TableVIII below.

                                      TABLE VIII                                  __________________________________________________________________________    COMPRESSIVE STRENGTHS USING VARYING AMOUNTS OF SURFACTANT                     Amount of Resin Composition                                                                  Amount Surfactant                                                                        Amount of Gel Breaker                                                                      Amount of Sand Used,                   Used, cc per Liter                                                                           Used, cc per Liter of                                                                    Used, cc per Liter of                                                                     lb. per Gallon of                                                                        Cure   Compressive           of Gelled Aqueous                                                                            Gelled Aqueous                                                                           Gelled Aqueous                                                                            Gelled Aqueous                                                                           Temperature,                                                                         Strength              Carrier Liquid Carrier Liquid                                                                           Carrier Liquid                                                                            Carrier Liquid                                                                           °F.                                                                           psi                   __________________________________________________________________________    16             2          1           4          160    2550                  16             3          1           4          160    2680                  16             4          1           4          160    4290                  __________________________________________________________________________

While that which is considered to be the preferred embodiments of theinvention has been described hereinbefore, it is to be understood thatmodifications and changes can be made in the methods and compositionswithout departing from the spirit or scope of the invention ashereinafter set forth in the claims.

What is claimed is:
 1. A method of continuously forming and suspendingconsolidatable resin composition coated particulate material in a gelledaqueous carrier liquid comprising intermixing substantially continuousstreams of said gelled aqueous carrier liquid, prepared by admixing fromabout 20 to 120 pounds of a hydratable polysaccharide having a molecularweight of from about 100,000 to about 4,000,000 with an aqueous carrierliquid per 1000 gallons of said carrier liquid, a particulate material,a resin composition which will subsequently harden and a surface activeagent whereby said particulate material is substantially continuouslycoated with said resin composition and suspended in said gelled aqueouscarrier liquid, said resin composition comprising a hardenablepolyepoxide resin, a hardening agent for said resin, a substantiallywater immiscible reactive diluent and substantially water immisciblenon-reactive diluent for said resin, said reactive and non-reactivediluents being present in said resin composition in amouns sufficient tolower the viscosity of the resin composition to a level in the range offrom about 100 to about 800 centipoises at ambient temperature.
 2. Amethod of claim 1 wherein said reactive diluent is present in an amountof from about 2 to about 35 parts per 100 parts by weight of saidpolyepoxide resin and said non-reactive diluent is present in an amountof from about 4 to about 20 parts per 100 parts by weight of saidpolyepoxide resin.
 3. The method of claim 1 wherein said non-reactivediluent is selected from the group consisting of compounds having thestructural formula: ##STR3## wherein R is (C_(n) H_(2n+1)) wherein n isan integer in the range of from about 1 to about 5;R₁ is (C_(m)H_(2m+1)) wherein m is O or an integer in the range of from 1 to about4, or ##STR4## wherein y is an integer in the range of from 1 to about4, and X is H or OH; and R₂ is C_(a) H_(2a) wherein a is an integer inthe range of from 2 to about
 5. 4. The method of claim 1 wherein saidreactive diluent comprises at least one member selected from the groupof butyl glycidyl ether, cresol glycidyl ether, alkyl glycidyl ether andphenyl glycidyl ether.
 5. The method of claim 1 wherein said gelledaqueous carrier liquid comprises an aqueous fluid gelled with apolysaccharide comprising at least one member selected from the group ofgalactomannon gum and derivatives thereof.
 6. The method of claim 1defined further to include admixing a crosslinking agent for saidpolysaccharide comprising at least one member from the group consistingof titanium, aluminum and zirconium chelates or salts and borate saltswith said gelled aqueous carrier liquid.
 7. The method of claim 1wherein said polyepoxide resin is comprised of the condensation productof epichlorohydrin and bisphenol A.
 8. The method of claim 1 whereinsaid hardening agent is a liquid eutectic mixture of methylene dianilineand metaphenylene diamine diluted with a water soluble solvent.
 9. Themethod of claim 1 wherein said surface active agent includes anon-cationic surfactant comprising at least one member selected from thegroup consisting of ethoxylated fatty acids produced by reacting fattyacids containing from about 12 to about 22 carbon atoms with from about5 to about 20 moles of ethylene oxide per mole of fatty acid andmixtures of said ethoxylated fatty acids with unreacted fatty acids. 10.A method of continuously forming and suspending consolidatable resincomposition coated particulate material in a gelled aqueous carrierliquid comprising intermixing substantially continuous streams of anaqueous carrier liquid gelled by the addition of a polysaccharidepolymer thereto, a particulate material, a surface active agentincluding a noncationic surfactant and a resin composition which willsubsequently harden whereby said particulate material is substantiallycontinuously coated with said resin composition and suspended in saidgelled aqueous carrier liquid, said resin composition comprising ahardenable polyepoxide resin, at least one substantially waterimmiscible first diluent for said resin, a second diluent which isnon-reactive with said resin and a hardening agent for said resin, saiddiluents being present in said resin composition in an amount sufficientto lower the viscosity of the resin composition to a level in the rangeof from about 100 to about 800 centipoises at ambient temperature andsaid polysaccharide is present in said aqueous carrier liquid in anamount of from about 20 to about 120 pounds per 1000 gallons of saidcarrier liquid.
 11. The method of claim 10 wherein said non-cationicsurfactant comprises at least one member selected from the groupconsisting of ethoxylated fatty acids produced by reacting fatty acidscontaining from about 12 to about 22 carbon atoms with from about 5 toabout 20 moles of ethylene oxide per mole of fatty acid and mixtures ofsaid ethoxylated fatty acids with unreacted fatty acids.
 12. The methodof claim 10 wherein said second diluent includes at least one memberselected from the group consisting of compounds having the structuralformula: ##STR5## wherein R is (C_(n) H_(2n+1)) wherein n is an integerin the range of from about 1 to about 5;R₁ is (C_(m) H_(2m+1)) wherein mis O or an integer in the range of from 1 to about 4 or ##STR6## therange of from about 1 to about 4 and X is H or OH; and R₂ is C_(a)H_(2a) wherein a is an integer in the range of from about 2 to about 5.13. The method of claim 12 wherein said substantially water immisciblediluent includes at least one member selected from the group of butylglycidyl ether, cresol glycidyl ether, allyl glycidyl ether and phenylglycidyl ether.
 14. The method of claim 10 wherein said polyepoxideresin is comprised of the condensation product of epichlorohydrin andbisphenol A and said hardening agent is a liquid eutectic mixture ofmethylene dianiline and metaphenylene diamine diluted with a watersoluble solvent.
 15. The method of claim 10 defined further to includethe steps of introducing the resulting substantially continuous streamof gelled aqueous carrier liquid having resin composition coatedparticulate material suspended therein into a zone in a subterraneanformation; and allowing said resin composition to harden whereby saidparticulate material is caused to form a hard permeable mass in saidzone.
 16. The method of claim 15 wherein said zone comprises at leastone member selected from the group of a wellbore penetrating saidsubterranean formation and a fracture created or present in saidsubterranean formation.
 17. The method of claim 10 wherein said seconddiluent comprises at least one member selected from the group consistingof compounds having the structural formula: ##STR7## wherein R is (C_(n)H_(2n+1)) wherein n is an integer in the range of from about 1 to about5;R₁ is C_(m) H_(2m+1)) wherein m is O or an integer in the range offrom about 1 to about 4 or ##STR8## wherein y is an integer in the rangeof from about 1 to about 4 and X is H or OH; and R₂ is C_(a) H_(2a)wherein a is an integer in the range of from about 2 to about 5, saidmember being present in an amount of from about 4 to about 20 parts per100 parts by weight of said polyepoxide resin and said first diluentcomprises at least one member selected from the group consisting ofbutyl glycidyl ether, cresol glycidyl ether, allyl glycidyl ether andphenyl glycidyl ether , present in an amount of from about 2 to about 35parts per 100 parts by weight of said polyepoxide resin.